US10744966B2 - Hybrid/composite energy-absorbing lower member for automobiles and process for making the same - Google Patents

Hybrid/composite energy-absorbing lower member for automobiles and process for making the same Download PDF

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Publication number
US10744966B2
US10744966B2 US16/063,076 US201616063076A US10744966B2 US 10744966 B2 US10744966 B2 US 10744966B2 US 201616063076 A US201616063076 A US 201616063076A US 10744966 B2 US10744966 B2 US 10744966B2
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Prior art keywords
metallic
composite component
vehicle
lower member
undertray
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US16/063,076
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US20190291667A1 (en
Inventor
Dinesh Munjurulimana
Pavan PURANIK
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SABIC Global Technologies BV
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SABIC Global Technologies BV
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/03—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by material, e.g. composite
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/04—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects formed from more than one section in a side-by-side arrangement
    • B60R19/12—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects formed from more than one section in a side-by-side arrangement vertically spaced
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
    • B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
    • B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/34—Protecting non-occupants of a vehicle, e.g. pedestrians

Definitions

  • This disclosure is directed to a hybrid/composite energy-absorbing lower member for vehicles. Moreover, the disclosure is directed to a method of making a hybrid/composite energy-absorbing lower member for vehicles.
  • a lower legform impact to a vehicle calls for maintaining three parameters (knee acceleration, knee bending and shear) within a prescribed value.
  • a lower member, such as a stiffener, a spoiler, an undertray and the like, present in a vehicle plays a crucial role in controlling lower legform impact such as knee bending.
  • Architecture of a lower member for a vehicle can be generally categorized into two different constructions. In the first, a lower steel spoiler is mounted at two ends, and in the second one an all plastic lower-spoiler/undertray is mounted across a lower portion of front end module at numerous locations.
  • the architectures of the lower member of conventional pedestrian friendly vehicles are shown in FIG. 1 and FIG. 2 .
  • the existing solutions of a lower member are either made of metal or plastic.
  • FIG. 1 shows a conventional metal spoiler 2 of a front-end module 1 connected either to metallic brackets 4 or to two relatively stiff structures where the metal spoiler 2 is used as a lower-leg protector.
  • the undertray typically gets support only from two ends in these vehicles through connections 3 .
  • FIG. 2 shows a conventional front-end module 10 having a plastic undertray 12 mounted at numerous locations 13 across the lower portion of the front end module 10 .
  • a solution using the typical plastic undertray 12 requires multiple mounting locations 13 on the front end module 10 in an attempt to meet the necessary regulatory requirements for pedestrian safety. These numerous mounting locations increase manufacturing complexity and time, increase costs, and so on.
  • the performance of the plastic undertray 12 reduces significantly if the mounting locations are reduced. For example, reduced to two mounting locations (Extreme ends).
  • the lower-leg impact performance (mainly the knee bending) of a vehicle with a plastic undertray 12 on these kinds of vehicles is shown in FIG. 3 .
  • the knee bending in the case of a pure plastic undertray 12 is significantly undesirably negatively greater than that observed using a metallic spoiler 2 . Therefore, the performance of a pure plastic undertray 10 system is not satisfactory although it provides a significant weight reduction.
  • the pure plastic undertray 10 requires complex manufacturing due to the plurality of attachments across the front end module.
  • the steel spoiler solution has more satisfactory pedestrian safety performance. However, the steel spoiler solution results in greater weight, increased cost and complex manufacturing through a need to have supporting plates/brackets and the like, which are separately stamped, manufactured and assembled together by welding/fasteners and the like.
  • an energy-absorbing lower member for automobiles having simplified manufacturing, simplified construction, improved pedestrian safety, and reduced weight is desired.
  • a hybrid lower member with plastics over molded on metallic/composite tubes or metallic/composite channels with standard sections may be used to meet the requirements for a front end module vehicle architecture.
  • the extra under shield which may be a part of a bumper fascia, can be simplified and the entire system weight can be reduced without compromising pedestrian safety performance of the system.
  • a lower member device includes a metallic/composite component extending substantially along a width of a plastic portion, the metallic/composite component including attachment portions configured to attach to a front end module of a vehicle, the plastic portion being over molded on the metallic/composite component, and the plastic portion further includes strengthening portions arranged adjacent the metallic/composite component.
  • a method of constructing a lower member device includes arranging a metallic/composite component in preparation for molding a plastic portion such that the metallic/composite component will extend along a width of the plastic portion, configuring the metallic/composite component to attach to a front end module of a vehicle with attachment portions, molding the plastic portion over the metallic/composite component, and forming strengthening portions arranged adjacent the metallic/composite component in the plastic portion during molding.
  • FIG. 1 shows a conventional metallic spoiler of a front end module of a vehicle.
  • FIG. 2 shows conventional plastic undertray of a front-end module of a vehicle.
  • FIG. 3 shows pedestrian safety impact performance for the conventional metallic spoiler and the conventional plastic undertray.
  • FIG. 4 illustrates components of a front end of a vehicle.
  • FIG. 5 illustrates a construction of a front end module according to an aspect of the disclosure.
  • FIG. 6 illustrates a construction of a lower member according to an aspect of the disclosure.
  • FIG. 7 illustrates a partial construction of a lower member and the connections to a vehicle according to an aspect of the disclosure.
  • FIG. 8A and FIG. 8B show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 9 shows pedestrian safety impact performance for a conventional metallic spoiler and the lower member according to the disclosure.
  • FIG. 10A , FIG. 10B , FIG. 10C , FIG. 10D , and FIG. 10E show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 11A , FIG. 11B , FIG. 11C , FIG. 11D , and FIG. 11E show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 12A , FIG. 12B , FIG. 12C , and FIG. 12D show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 13A , FIG. 13B , FIG. 13C , FIG. 13D , and FIG. 13E show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 14A , FIG. 14B , FIG. 14C , FIG. 14D , and FIG. 14E show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 15A , FIG. 15B , FIG. 15C , FIG. 15D , FIG. 15E , and FIG. 15F show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 16A , FIG. 16B , FIG. 16C , and FIG. 16D show various cross-sections of a lower member according to other aspects of the disclosure.
  • One aspect of the disclosure is to provide a lower member energy-absorbing system at the front portion of the vehicle with plastic over molded on metallic or composite channels or tubes.
  • Another aspect of the disclosure is to provide a design of a hybrid/metal plastic/composite energy-absorbing lower member whose metallic/composite member is mounted to the end supports of the lower portion of the vehicle using standard fastening elements such as clips, bolts, rivets etc.
  • a hybrid/composite solution as set forth in the disclosure is proposed to replace the existing metal solution.
  • the lower portion of the fascia which is typically known as an undercover or a guard, can be removed, and the metal plastic/composite lower member can serve the function of a lower stiffener, spoiler and/or an underguard.
  • the metallic/composite part may be constructed utilizing a readily available metallic/composite pipe with a circular or a rectangular cross section resulting in reduced manufacturing costs and simplified construction.
  • a fastener such as a C-section metal clamp, may be used to mount the hybrid/composite lower member to an upper cross member of a vehicle.
  • This metal pipe/standard shape metal component or composite channel may then be over molded with plastic to bear the load.
  • This hybrid/composite lower member meets the regulatory requirements as evidenced by numerous tests discussed below. Moreover, the hybrid/composite lower member results in a significant weight savings. Hence, the hybrid/composite lower member reducing the weight of the system without compromising the regulatory safety requirements.
  • FIG. 4 illustrates components of a front end of a vehicle.
  • FIG. 4 is a partial cross-sectional view of one aspect of a front end of a vehicle 400 including a bumper beam 430 , an energy absorber (EA) 426 , a fascia 424 , a hood, a radiator 432 , and a lower member 420 .
  • EA energy absorber
  • the front of the vehicle 400 may include many additional components. However, these additional components are not shown to simplify illustration.
  • FIG. 5 illustrates the construction of a front end module according to an aspect of the disclosure.
  • FIG. 5 shows some components of the front end module 500 including the lower member 420 and attachments 130 that are configured to attach the lower member 420 to the front end module 500 .
  • the front end module 500 may further include brackets 140 that are configured to attach the front end module 500 to a frame (not shown) of the vehicle 400 .
  • brackets 140 that are configured to attach the front end module 500 to a frame (not shown) of the vehicle 400 .
  • the lower member 420 is constructed such that two attachments 130 are utilized in order to provide attachment of the lower member 420 to the front end module 500 and provide satisfactory pedestrian safety impact performance as described below. Utilizing a construction having two attachments 130 simplifies construction, reduces manufacturing time, reduces parts count, and the like.
  • the front end module 500 may be associated with the vehicle 400 of FIG. 4 and may further include the bumper beam 430 , the energy absorber (EA) 426 , the fascia 424 , the hood, and the radiator 432 .
  • the vehicle 400 may further include numerous other components that are not illustrated including an engine, an engine compartment, transmission, ground engaging members such as wheels and tires, exhaust system, fuel system, and the like.
  • FIG. 6 illustrates the construction of a lower member according to an aspect of the disclosure.
  • FIG. 6 illustrates a backside of the lower member 420 .
  • the lower member 420 may include a metallic/composite component 602 extending generally horizontally along a width of the lower member 420 from one end to another end (along the X axis).
  • the metallic/composite component 602 may not extend to the very ends of the lower member 420 .
  • the metallic/composite component 602 may only extend horizontally to a location of the fasteners 606 .
  • the metallic/composite component 602 may extend horizontally to a location just past the fasteners 606 and not extend to the very ends of the lower member 420 .
  • the ends of the metallic/composite component 602 adjacent a location of the fasteners 606 may form attachment portions.
  • the metallic/composite component 602 may be arranged at any height position in the lower member 420 (the height extending along the Y axis).
  • the metallic/composite component 602 may be steel, aluminum, titanium, glass filed or carbon composite and the like.
  • the metallic/composite component 602 may be over molded into the construction of the lower member 420 .
  • the lower member 420 may fully surround the metallic/composite component 602 .
  • the lower member 420 may partially surround the metallic/composite component 602 .
  • the lower member 420 may surround the metallic/composite component 602 such that an upper surface of the metallic/composite component 602 is exposed.
  • the lower member 420 may surround the metallic/composite component 602 such that only the ends of the metallic/composite component 602 are exposed adjacent the fasteners 606 .
  • the lower member 420 may surround the metallic/composite component 602 such that only a portion of the attachment portions of the metallic/composite component 602 are exposed adjacent the fasteners 606 . In another aspect, the lower member 420 may partially surround the metallic/composite component 602 such that the attachment portions of the metallic/composite component 602 are exposed adjacent the fasteners 606 .
  • the lower member 420 may be further molded with a plurality of strengthening structures 604 .
  • the strengthening structures 604 may be ribs, areas of greater thickness, and the like.
  • the strengthening structures 604 may be a solid portion, a foamed portion, a hollow portion, and the like.
  • the strengthening structures 604 may be combinations of the same.
  • the strengthening structures 604 may include rectangular cross-section portions.
  • the strengthening structures 604 may include trapezoidal cross-section portions.
  • the strengthening structures 604 may include other polygonal and non-polygonal cross-section portions as needed to provide the required and/or desired strength of the lower member 420 .
  • the strengthening structures 604 may be adjacent, encase, and/or cover the metallic/composite component 602 .
  • the lower member 420 may include a smooth exposed paintable outer surface (not shown).
  • the lower member 420 may further include open sections 612 between the strengthening structures 604 to reduce weight of the lower member 420 .
  • the construction of the metallic/composite component 602 is described in further detail below.
  • the lower member 420 may be installed on the vehicle 400 , below the bumper beam 430 .
  • the outer surface of the lower member 420 may form a lower portion of the fascia 424 .
  • the lower member 420 may be separately covered by the fascia 424 .
  • FIG. 7 illustrates a partial construction of a lower member and the connections to a vehicle according to an aspect of the disclosure.
  • the lower member 420 may be fastened directly to end supports 702 that may extend from the vehicle 400 and/or from the front end module 500 .
  • the end supports 702 may be fastened to the metallic/composite component 602 with fasteners 606 .
  • the fasteners 606 may be bolts, rivets, screws, clamps, and the like.
  • the fastener may be implemented as a C clamp that provides a rigid connection and also provides an efficient and rapid manufacturing approach.
  • the metallic/composite component 602 may be exposed or not covered by the lower member 420 at the ends (along the X axis) of the metallic/composite component 602 at the attachment portions. This construction of the lower member 420 may allow the end supports 702 to readily connect to the metallic/composite component 602 .
  • the end supports 702 may have a particular width W 2 along the X axis; and as shown in FIG. 6 , the lower member 420 may have a width W 1 along the X axis.
  • the width W 2 of the end supports 702 may be 5%-25% of the width W 1 of the lower member 420 .
  • FIG. 8A and FIG. 8B show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 8A shows the metallic/composite component 602 configured as a circular metallic/composite pipe arranged in a channel of the lower member 420 .
  • the plastic portion of the lower member 420 is over molded around the metallic/composite component 602 configured as a circular metallic/composite pipe.
  • the lower member 420 may further include one or more strengthening structures 604 to provide additional strength to the lower member 420 .
  • FIG. 8B shows the metallic/composite component 602 configured as a metallic/composite channel arranged in a channel of the lower member 420 .
  • the plastic portion of the lower member 420 is over molded around the metallic/composite component 602 configured at a metallic/composite channel.
  • the lower member 420 may further include a strengthening structure 604 to provide additional strength to the lower member 420 .
  • the lower member 420 may further include an open section 612 to reduce weight of the lower member 420 .
  • the lower member 420 may further include a rib structure 608 to provide additional strength to the lower member 420 .
  • FIG. 9 shows pedestrian safety impact performance for a conventional metallic/composite spoiler and the lower member according to the disclosure.
  • the lower member 420 provides superior performance in pedestrian vehicle impacts from 5 to 15 ms (milliseconds) in comparison to a conventional steel spoiler (consisting essentially of the same components, but formed form steel) with respect to knee rotation. Otherwise the lower member 420 provides comparable performance in pedestrian vehicle impacts with respect to the conventional steel spoiler with respect to knee rotation. Accordingly, the lower member 420 also provides superior performance in pedestrian vehicle impacts during all time frames in comparison to a conventional plastic undertray with respect to knee rotation with reference to FIG. 3 . Moreover, the lower member 420 should provide commensurate superior performance in all types of pedestrian to vehicle impacts in comparison to the conventional steel spoiler and the conventional plastic undertray.
  • FIG. 10A , FIG. 10B , FIG. 10C , FIG. 10D , and FIG. 10E show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 10A shows another aspect with the metallic/composite component 602 configured as a circular metallic/composite pipe arranged in a channel of the lower member 420 .
  • the plastic portion of the lower member 420 is over molded around the metallic/composite component 602 configured as a circular metallic/composite pipe.
  • the lower member 420 may further include a strengthening structure 604 to provide additional strength to the lower member 420 .
  • the lower member 420 may further include a rib structure 608 to provide additional strength to the lower member 420 .
  • the lower member 420 may further include an additional area of thickness 610 to provide additional strength to the lower member 420 .
  • FIG. 10B shows another aspect with the metallic/composite component 602 configured as a circular metallic/composite pipe arranged in a channel of the lower member 420 with the rib structure 608 and an open section 612 .
  • FIG. 10C shows another aspect with the metallic/composite component 602 configured as a circular metallic/composite pipe arranged in a channel of the lower member 420 .
  • the lower member 420 may further include a strengthening structure 604 to provide additional strength to the lower member 420 .
  • FIG. 10D shows another aspect with the metallic/composite component 602 configured as a rectangular metallic/composite pipe arranged in a channel of the lower member 420 .
  • FIG. 10E shows another aspect with the metallic/composite component 602 configured as a hexagon shaped metallic/composite pipe arranged in a channel of the lower member 420 .
  • FIG. 11A , FIG. 11B , FIG. 11C , FIG. 11D , and FIG. 11E show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 11A shows another aspect with the metallic/composite component 602 configured as a circular metallic/composite pipe arranged in a channel of the lower member 420 .
  • the plastic portion of the lower member 420 is over molded around the metallic/composite component 602 configured as a circular metallic/composite pipe.
  • the lower member 420 may further include a strengthening structure 604 to provide additional strength to the lower member 420 .
  • the lower member 420 may further include a rib structure 608 to provide additional strength to the lower member 420 .
  • the lower member 420 may further include an additional area of thickness 610 to provide additional strength to the lower member 420 .
  • FIG. 11B shows another aspect with the metallic/composite component 602 configured as a circular metallic/composite pipe arranged in a channel of the lower member 420 having a rib structure 608 .
  • FIG. 11C shows another aspect with the metallic/composite component 602 configured as a half circular metallic/composite pipe arranged in a channel of the lower member 420 .
  • FIG. 11D shows another aspect with the metallic/composite component 602 configured as a rectangular shaped metallic/composite pipe arranged in a channel of the lower member 420 .
  • FIG. 11E shows another aspect with the metallic/composite component 602 configured as a metallic/composite flared channel arranged in a channel of the lower member 420 .
  • FIG. 12A , FIG. 12B , FIG. 12C , and FIG. 12D show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 12A shows another aspect with the metallic/composite component 602 configured as a circular metallic/composite pipe arranged in a channel of the lower member 420 .
  • the plastic portion of the lower member 420 is over molded around the metallic/composite component 602 configured as a circular metallic/composite pipe.
  • the lower member 420 may further include a strengthening structure 604 to provide additional strength to the lower member 420 .
  • the lower member 420 may further include an additional area of thickness 610 to provide additional strength to the lower member 420 .
  • FIG. 12B shows another aspect with the metallic/composite component 602 configured as a curved side metallic/composite square arranged in a channel of the lower member 420 .
  • FIG. 12C shows another aspect with the metallic/composite component 602 configured as a half circular metallic/composite pipe arranged in a channel of the lower member 420 .
  • FIG. 12D shows another aspect with the metallic/composite component 602 configured as a curved side metallic/composite channel arranged in a channel of the lower member 420 .
  • FIG. 13A , FIG. 13B , FIG. 13C , FIG. 13D , and FIG. 13E show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 13A shows another aspect with the metallic/composite component 602 configured as a circular metallic/composite rod arranged in a channel of the lower member 420 .
  • a metallic/composite rod is configured with a solid metallic/composite construction.
  • the plastic portion of the lower member 420 is over molded around the metallic/composite component 602 configured as a circular metallic/composite rod.
  • the lower member 420 may further include a strengthening structure 604 to provide additional strength to the lower member 420 .
  • the lower member 420 may further include an additional area of thickness 610 to provide additional strength to the lower member 420 .
  • FIG. 13B shows another aspect with the metallic/composite component 602 configured as a rectangular metallic/composite rod arranged in a channel of the lower member 420 .
  • FIG. 13C shows another aspect with the metallic/composite component 602 configured as a hexagon shaped metallic/composite rod arranged in a channel of the lower member 420 .
  • FIG. 13D shows another aspect with the metallic/composite component 602 configured as an elliptical metallic/composite rod arranged in a channel of the lower member 420 .
  • FIG. 13E shows another aspect with the metallic/composite component 602 configured as a four curved sided metallic/composite rod arranged in a channel of the lower member 420 .
  • FIG. 14A , FIG. 14B , FIG. 14C , FIG. 14D , and FIG. 14E show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 14A shows another aspect with the metallic/composite component 602 configured as a half circular metallic/composite rod arranged in a channel of the lower member 420 .
  • FIG. 14B shows another aspect with the metallic/composite component 602 configured as a rectangular metallic/composite rod arranged in a channel of the lower member 420 .
  • FIG. 14C shows another aspect with the metallic/composite component 602 configured as a trapezoid shaped metallic/composite rod arranged in a channel of the lower member 420 .
  • FIG. 14A , FIG. 14B , FIG. 14C , FIG. 14D , and FIG. 14E show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 14A shows another aspect with the metallic/composite component
  • FIG. 14D shows another aspect with the metallic/composite component 602 configured as a half elliptical metallic/composite rod arranged in a channel of the lower member 420 .
  • FIG. 14E shows another aspect with the metallic/composite component 602 configured as a metallic/composite rod with a flat sided shape having three curved sides arranged in a channel of the lower member 420 .
  • FIG. 15A , FIG. 15B , FIG. 15C , FIG. 15D , FIG. 15E , FIG. 15F , FIG. 15G , and FIG. 15H show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIG. 15A shows another aspect with the metallic/composite component 602 configured as a half circular metallic/composite rod arranged in a channel of the lower member 420 with the flat side up as shown in the Figure.
  • FIG. 15B shows another aspect with the metallic/composite component 602 configured as a trapezoid shaped metallic/composite rod arranged in a channel of the lower member 420 with the wider side up as shown in the Figure.
  • FIG. 15A shows another aspect with the metallic/composite component 602 configured as a half circular metallic/composite rod arranged in a channel of the lower member 420 with the flat side up as shown in the Figure.
  • FIG. 15B shows another aspect with the metallic/composite component 602 configured as
  • FIG. 15C shows another aspect with the metallic/composite component 602 configured as a half elliptical metallic/composite rod arranged in a channel of the lower member 420 with the flat side up as shown in the Figure.
  • FIG. 15D shows another aspect with the metallic/composite component 602 configured as a metallic/composite rod with a flat top shape having three curved sides arranged in a channel of the lower member 420 with the flat side up as shown in the Figure.
  • FIG. 15E shows another aspect with the metallic/composite component 602 configured as a half circular metallic/composite rod arranged in a channel of the lower member 420 with the flat side down as shown in the Figure.
  • FIG. 15F shows another aspect with the metallic/composite component 602 configured as a trapezoid shaped metallic/composite rod arranged in a channel of the lower member 420 with the wider side down as shown in the Figure.
  • FIG. 15G shows another aspect with the metallic/composite component 602 configured as a half elliptical metallic/composite rod arranged in a channel of the lower member 420 with the flat side down as shown in the Figure.
  • FIG. 15H shows another aspect with the metallic/composite component 602 configured as a metallic/composite rod with a flat bottomed shape having three curved sides arranged in a channel of the lower member 420 with the flat side up as shown in the Figure.
  • FIG. 16A , FIG. 16B , FIG. 16C , and FIG. 16D show various cross-sections of a lower member according to other aspects of the disclosure.
  • FIGS. 16A, 16B, 16C, and 16D show various structural arrangements that include the metallic/composite component 602 configured as a metallic/composite rod arranged in a channel of the lower member 420 .
  • the plastic portion of the lower member 420 is over molded around the metallic/composite component 602 configured as a circular metallic/composite rod.
  • the lower member 420 may further include various arrangements of a strengthening structure 604 to provide additional strength to the lower member 420 , a rib structure 608 to provide additional strength to the lower member 420 , an additional area of thickness 610 to provide additional strength to the lower member 420 , and open sections 612 to reduce weight of the lower member 420 .
  • the process of constructing the lower member 420 may utilize any known molding technology.
  • the process of constructing the lower member 420 may utilize any known polypropylene molding technology.
  • the process may include arranging the metallic/composite component 602 in preparation for molding the lower member 420 such that the metallic/composite component may extend along a width of the lower member. This may include arranging the metallic/composite component within a mold prior to molding. Before arranging or after arranging, the metallic/composite component 602 may be configured to attach to a front end module of the vehicle as described above. Thereafter, a plastic portion may be over molded with respect to the metallic/composite component 602 .
  • the lower member 402 may have the strengthening structures 604 , open sections 612 , and rib structures 608 formed adjacent the metallic/composite member in the plastic portion.
  • a hybrid/composite lower member system was constructed consistent with the disclosure to replace an existing steel spoiler solution.
  • the existing steel spoiler solution had a mass of approximately 3.1 kg.
  • the hybrid/composite lower member system constructed consistent with the disclosure had a mass of approximately 2 kg (approximate 1 kg of plastic filled resin and 1 kg of steel). This resulted in more than 1 kg weight savings for the vehicle, which is at least a 30% reduction in weight. A similar percentage of weight reduction would be achieved in other constructions.
  • the hybrid/composite lower member system was constructed consistent with the disclosure resulted in beneficial part integrations.
  • the hybrid/composite lower member system constructed consistent with the disclosure resulted in reduced manufacturing complexity, reduced manufacturing time, and had a cost comparable to the conventional steel spoiler.
  • the hybrid/composite lower member system was constructed consistent with the disclosure had favorable performance with respect to rotation of leg during lower-leg impact tests.
  • a lower member device comprising: a metallic/composite component extending substantially along a width of the lower member; the metallic/composite component is configured to attach to a front end module of the vehicle; a plastic portion over molded on the metallic/composite component; and the plastic portion further comprises strengthening portions arranged adjacent the metallic/composite member.
  • Example 1 The device of Example 1, wherein the metallic/composite component is configured to be mechanically fastened to end supports extending from the front end module of the vehicle with mechanical fasteners.
  • the metallic/composite component comprises a metallic/composite rod.
  • the metallic/composite component comprises a rod having a polygonal cross-section.
  • the metallic/composite component comprises a rod having a non-polygonal cross-section.
  • a vehicle comprising the lower member of any one of Examples 1-11 and further comprising: a radiator; an engine compartment; and an energy absorbing system comprising an energy absorber.
  • Example 12 The vehicle of Example 12, further comprising a bumper beam, wherein the energy absorber extends parallel to the bumper beam.
  • a method of constructing a lower member device comprising: arranging a metallic/composite component in preparation for molding the lower member such that the metallic/composite component will extend along a width of the lower member; configuring the metallic/composite component to attach to a front end module of the vehicle; molding a plastic portion over the metallic/composite component; and forming strengthening portions arranged adjacent the metallic/composite member in the plastic portion.
  • Example 14 further comprising configuring the metallic/composite component to be mechanically fastened to end supports extending from the front end module of the vehicle with mechanical fasteners.
  • plastic portion further comprises ribs.
  • the lower member 420 may be constructed with filled polypropylene (PP) and a steel reinforcement component.
  • the lower member 420 may include any thermoplastic material or combination of thermoplastic materials with another material (e.g., with elastomeric materials and/or thermoset materials), such as a filled thermoplastic polyolefin (TPO).
  • TPO thermoplastic polyolefin
  • thermoplastic materials include polybutylene terephthalate (PBT); acrylonitrile-butadiene-styrene (ABS); polycarbonate; polycarbonate/PBT blends; polycarbonate/ABS blends; copolycarbonate-polyesters; acrylic-styrene-acrylonitrile (ASA); acrylonitrile-(ethylene-polypropylene diamine modified)-styrene (AES); phenylene ether resins; blends of polyphenylene ether/polyamide; polyamides; phenylene sulfide resins; polyvinyl chloride PVC; high impact polystyrene (HIPS); low/high density polyethylene (L/HDPE); expanded polypropylene (EPP); and thermoplastic olefins (TPO), as well as filled (e.g., glass filled) materials of above resins.
  • PBT polybutylene terephthalate
  • ABS acrylonitrile-butadiene-st
  • a lower member and, optionally the energy absorber comprise XenoyTM resin, which is commercially available from SABIC Innovative Plastics IP B.V.
  • An exemplary filled resin is STAMAXTM resin, which is a long glass fiber filled polypropylene resin also commercially available from SABIC Innovative Plastics IP B.V.
  • the bumper beam and/or energy absorber can also be formed from combinations comprising at least one of any of the above-described materials.
  • the disclosure provides a hybrid/composite energy-absorbing lower member for automobiles with plastics over molded on at least one metal component having a simplified construction, improved pedestrian safety, and reduced weight. Moreover, the disclosure provides a method of making a hybrid/composite energy-absorbing lower member having a simplified construction, improved pedestrian safety, and reduced weight.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Body Structure For Vehicles (AREA)
US16/063,076 2015-12-23 2016-12-14 Hybrid/composite energy-absorbing lower member for automobiles and process for making the same Active US10744966B2 (en)

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IN4249DE2015 2015-12-23
IN4249/DEL/2015 2015-12-23
PCT/IB2016/057629 WO2017109647A1 (en) 2015-12-23 2016-12-14 Hybrid/composite energy-absorbing lower member for automobiles and process for making the same

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US20190291667A1 US20190291667A1 (en) 2019-09-26
US10744966B2 true US10744966B2 (en) 2020-08-18

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EP (1) EP3393861A1 (zh)
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FR3070665B1 (fr) * 2017-09-07 2019-09-13 Compagnie Plastic Omnium Piece monobloc formant un bloc avant comportant un systeme d'absorption et un systeme aerodynamique

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WO2017109647A1 (en) 2017-06-29
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US20190291667A1 (en) 2019-09-26

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